WO2014118398A1

WO2014118398A1 - Ergonomic shower tray and method for manufacturing same

Info

Publication number: WO2014118398A1
Application number: PCT/ES2013/070056
Authority: WO
Inventors: Javier ANDRÉS ALEMANY
Original assignee: Solid Soft Tray, S.L.
Priority date: 2013-02-01
Filing date: 2013-02-01
Publication date: 2014-08-07
Also published as: EP2952128A1; US20160007810A1; EP2952128B1; ES2875053T3

Abstract

The invention relates to an ergonomic shower tray (1), which includes: a planar base surface (2); an upper surface (3a) opposite said planar base surface (2), wherein said upper surface (3a) includes, in the perimeter area thereof, planar surfaces suitable for placing a screen or the like; at least one drainage line (4) and a drainage area (3b) around said line which includes at least one offset (3) with a slope of 0.5% to 2%, which drops towards the at least one drainage line (4); and an area (3c) adjacent to the drainage area (3b) defined by the remaining planar surface of said upper surface (3a) of the shower tray (1); wherein the tray has a thickness of 1.75 cm to 3.25 cm and wherein the material of said shower tray (1) includes integral polyurethane that defines a plurality of cavities inside the shower tray (1), making same resilient such that the tray can adapt to the footprint of a user.

Description

ERGONOMIC SHOWER TRAY AND MANUFACTURING PROCEDURE OF

SAME

D E S C R I P C I Ó N

TECHNICAL FIELD OF THE INVENTION

The present invention relates to an ergonomic shower tray and the manufacturing process thereof; where the shower tray and the manufacturing process are framed in the field of bathrooms and toilets and, preferably, in domestic bathrooms.

The purpose of this manufacturing process is to obtain an ergonomically designed shower tray, whose manufacture includes a series of reduced steps, without having to make a premix of materials for subsequent injection into a mold, and suitable for provision on flat surfaces of homes or public bathrooms.

BACKGROUND OF THE INVENTION

By way of introduction, the shower trays currently used are preferably made of ceramic, acrylic or stainless steel; that is to say, they are rigid materials that are fixed in work on a floor or forged by means of a mortar, plaster or other adhesive paste type adhesive material.

Such plates have varied disadvantages ranging from fragility to impacts, accentuated in ceramic material, to the difficulty of forming varied geometries due to the difficulty of machinability of such materials, being normally very abrasive and, therefore, increasing the cost of machining of the shower tray to be manufactured. That is why, to solve this problem, different applications are known where the possibility of forming and manufacturing shower trays with different materials is raised, see for example Spanish patent publication number 2329641, which describes the procedure for manufacture of a shower tray, which is manufactured by molding with a flexible material that must necessarily be materialized in reduced thickness to adapt to the work floor and where said work floor must necessarily comprise a certain concavity or fall, previously constructed, towards an interior point where a drain pipe is located, and therefore a shower tray of flexible character is obtained by being made of flexible materials, but which requires that the floor or work floor comprises an inclination towards the drain, increasing the construction time of the floor and, therefore, needing more expensive and complicated facilities adas

That is why, in view of the aforementioned drawbacks, it is necessary to create a new shower tray and forming procedure that allows its arrangement on surfaces or screeds without the need to previously build inclinations, falls or any concavity. on said surfaces or screeds towards a drain point, which additionally endows it with a degree of elasticity suitable to adapt to the user's footprint, in addition to specifying a reduced number of stages in its manufacture that directly results in a reduced cost of manufacture of said product.

DESCRIPTION OF THE INVENTION

The present invention relates to an ergonomic shower tray, and the manufacturing and forming process thereof; where said shower tray comprises the following technical characteristics:

A flat base surface suitable for placing on a flat surface, hereinafter referred to as Solera;

an upper surface opposite said flat base surface, wherein said upper surface comprises in the perimeter zone, flat surfaces suitable for the placement of a screen or the like, at least one drain pipe and a drain zone around said drain pipe that it comprises at least one slope that falls towards at least one drain pipe and an area adjacent to the drain zone defined by the remaining flat surface of said upper surface of the shower tray; and where the material of said shower tray comprises integral polyurethane that defines a plurality of internal cavities to the shower tray, giving rise to a shower tray provided with a certain elasticity and adaptable to the footprint of a user.

The existence of two differentiated areas on the upper surface of the ergonomic shower tray object of invention, the drain zone of the shower tray, in which at least one slope suitable for forcing the evacuation of the water located on the plate is highlighted of shower and the flat area defined by the perimeter zone suitable for coupling a screen or similar and the flat area adjacent to the drain zone.

In relation to the type of material and the recesses that are part of the shower tray, it is observed that such recesses allow the shower tray object of the invention to be elasticized, so that said shower tray adapts to the user's footprint when it it is placed on the plate, improving the ergonomics of the product and, in this way, it improves the grip of said user on the shower tray, so that the friction between the foot and the shower tray increases, improving the security perceived by the user.

It is observed that the shower tray comprises a base surface, which can comprise different geometries depending on the geometry of the floor where it is to be installed, but that said base surface is flat, then it is not necessary of masonry or expensive or complicated facilities to manufacture the hearth, if not that it is the shower tray itself that comprises said, at least one, unevenness located on the surface where the user is located, that is, in the drainage area of the upper surface opposite said flat base surface; and where said slope falls towards said, at least one, drain pipe to extract water from the area of the shower tray in a gravitational manner.

This solution results in the shower tray having a thickness greater than the average thickness of shower trays, since the unevenness has to be such that it allows a proper drainage of the shower water by said at least one drain. but where the increase in thickness compensates the cost of having to manufacture the unevenness in the solera itself, and freeing the masons in charge of forming and manufacturing the workload. Such thicknesses are in the defined range between 2 cm and 3 cm with a tolerance of +/- 0.25 cm; then they differ from the usual thicknesses of the shower trays currently known, as described in order to guarantee the correct evacuation of water and provide the shower tray with an ergonomic elasticity for the user.

The possibility is contemplated that said, at least one, unevenness comprises an inclination in the drainage zone comprised in the defined interval between 0.5% and 2% of slope, guaranteeing the correct evacuation of the shower water towards said, at least one, drain.

Additionally, the possibility that the upper surface of the shower tray comprises two zones is contemplated:

A wet area defined by the drainage zone comprising said at least one unevenness and part of the perimeter flat surfaces suitable for the placement of a screen or the like; that is, the area where the user takes a shower and that logically includes the area of the unevenness as well as part of the flat perimeter surfaces where it is contemplated the possibility of placing the screen or the partition wall; and a drying zone defined by the remaining flat surface of said upper surface of the shower tray, which is preferably located in the area opposite the drain pipe and helps the user to enter and exit the shower, since it comprises the flat area adjacent to the drain zone and part of the flat perimeter surfaces.

The possibility is contemplated that the drainage zone or wet area of the upper surface of the shower tray comprises a rectangular shape with a greater side comprised between 1 10 cm and 150 cm.

Likewise, the possibility is contemplated that the drain pipe is displaced with respect to the geometric center of the shower tray, regardless of the shape of the drain zone or wet zone of said shower tray.

Additionally, since the shower tray is provided with elasticity, it is contemplated that it comprises a plate on the flat base surface, aligned in correspondence with the drain pipe of the upper surface, which provides consistency to said section and prevents subsidence or irregularities in the base surface of the shower tray that could cause leaks, water losses, mismatches or the like when lowering a drain or siphon system in the shower tray.

Preferably, the material of said plate is made of galvanized iron or of similar characteristics, of reduced thickness and at least partially embedded in the base surface of the shower tray.

As regards the manufacturing process of the shower tray described above, the possibility is contemplated that, from a mold comprising the geometry of said shower tray, such a procedure comprises the following steps: a) Inject into the mold a mixture of materials comprising polyol and isocyanate to obtain integral polyurethane, foaming agents and polyurethane pigment;

b) wait for a time of foaming and reaction of said previous material mixture, until cooling of the material mixture that forms the shower tray; Y

c) remove the shower tray formed inside said mold. In step a), it is observed that the mixture of materials comprises foaming agents, and therefore there is occluded air inside the shower tray that allows it to be provided with a degree of elasticity, even capable of slightly deforming when the user stands on East. It is therefore observed that the shower tray is manufactured as a product derived from a reaction, then occurs in a single step summarized in the injection of a mixture of materials already prepared, which is allowed to react and cool for extraction of the piece already ready. In relation to the arrangement of the shower tray manufactured to a certain geometry of a flat hearth, it is usual to have to cut the shower tray adapting it to the geometry of said hearth, so that when cutting a plurality of interior cavities corresponding to the inclusion of air inside, and in order to prevent the entry of water through such cavities, the possibility of finishing off the walls of the cuts with a type material, for example polyurethane putty and a certain percentage of water, is contemplated, so that prevents the passage of water into the shower tray.

This drawback is not reflected in the upper surface of the shower tray, since the injection molding manufacturing process itself and the pressure with which said mixture of materials is injected, results in the shower tray surfaces formed a waterproofing surface or skin of a certain thickness (usually around 2 mm) that prevents the passage of water or the formation of water remains due to osmosis. In relation to the mixture of materials, the possibility is contemplated that in step a), the mixture of materials comprises polyol and isocyanate to obtain integral polyurethane, where preferably, the obtaining of integral polyurethane is carried out according to the selection of a 50% isocyanate and polyol mixing program.

Additionally, the possibility is contemplated that in step a), the material mixture comprises polyurethane pigment, which are added to the original material mixture in a preferred percentage between 2% and 5% of the total material mixture.

In relation to the stages prior to the injection of the mixture of materials described above, the possibility is contemplated that prior to stage a), the process comprises the following steps: a1) Apply release agents on the inner surface of the mold that conforms the geometry of the shower tray to be shaped; Y

a2) paint said, at least one, inner surface of the mold of a final color of the shower tray to be formed.

Where, preferably, the release agents comprise a mixture of diluted silicone and semi-transparent wax, the application of which is carried out by means of an air spray gun on the at least one inner surface that forms the external geometry of the shower tray.

In a complementary way, the possibility is contemplated that after stage c), the procedure comprises the following stages: c1) Deburring the burrs existing in the shaped shower tray; Y

c2) clean the existing mold release agents on the surface of the shaped shower tray. Once the shower tray is clean, the shower tray is protected by means of a film, in addition to performing a quality control on said shower tray.

Subsequently, the possibility of selecting the drain grate to be installed, and the corresponding coupling means thereof to the shaped shower tray, is contemplated.

Additionally, and in relation to the adaptation of the geometry of the shower tray to the geometry of the flat floor where it is placed, the possibility is contemplated that after stage c), the procedure comprises the following stages: d) Cut the shower tray shaped according to the measures of a hearth where it will be located; Y

e) top off the cut surfaces with a waterproof material.

Finally, the possibility of applying a series of treatments to the manufactured shower tray is contemplated, so that later to stage c), the procedure comprises:

The application of an antibacterial treatment based on silver ions, and / or

the application of a non-slip treatment based on non-slip polyurethane.

Thus, according to the described invention, the ergonomic shower tray, and the method of forming it, constitute an important novelty in procedures for forming shower trays and their visual appearance, since it allows said shower tray to be installed in any type of flat and preferably level floor, either on the floor itself, flush or even raised above a support, without having to previously have inclined planes or concavities in the floor itself, have a degree of elasticity that improves the product ergonomics formed in addition to having a small number of stages in the forming of said shower tray.

DESCRIPTION OF THE DRAWINGS

To complement the description that is being made, and in order to help a better understanding of the features of the invention, according to a preferred example of practical realization thereof, a series of figures are attached as an integral part of said description. where, for illustrative and non-limiting purposes, the following has been represented: Figure 1 .- Shows a schematic elevational view of the shower tray object of the invention with two cross-sections, a first cut AB and a second cut CD.

Figure 2 shows a schematic view of the cross-sectional section A-B shown in Figure 1.

Figure 3 shows a schematic view of the cross-section section C-D shown in Figure 1. Figure 4.- They show a perspective view of the shower tray with the corresponding drain.

PREFERRED EMBODIMENT OF THE INVENTION

As can be seen in Figures 1 to 4, the ergonomic shower tray (1) that the invention describes comprises: A flat base surface (2) suitable for being placed on a flat surface or floor; Y

a series of slopes (3) located on the upper surface (3a) opposite said flat base surface (2); where said slopes (3) fall towards a drain pipe (4) shown in figures 1 and 4, in which there are two distinct zones, practically imperceptible to the user, which have the following particularities:

• A drying zone in an adjacent area (3c) to a drain zone (3b) of the shower tray (1), and defined by a series of flat perimeter surfaces suitable for placing a screen or similar, as well as a flat surface of smaller surface than the drain zone (3b) and suitable for the user to enter or leave the shower as such; Y

• a drain zone (3b) or wet area around the drain pipe (4) and defined by the slopes (3) that fall into the drain pipe (4) and the remaining flat perimeter surfaces.

The drain zone (3b) or wet area of the upper surface (3a) of the shower tray (1) comprises a rectangular shape, in which the drain pipe is offset from the geometric center of the shower tray (1).

In relation to the manufacturing process of the foamed shower tray (1) described above, it is based on a mold comprising the geometry of said shower tray (1), and the manufacturing process comprises the following steps: a) Apply release agents on the inner surface of the mold that forms the geometry of the shower tray (1) to be shaped;

b) paint the inner surface of the mold with a final color of the shower tray (1) to be shaped;

c) injecting into the mold a mixture of materials comprising: polyol and isocyanate to obtain integral polyurethane, foaming agents and a small percentage of polyurethane pigments;

d) wait for a foaming and reaction time of said previous material mixture, until cooling of the material mixture that forms the shower tray;

e) remove the shower tray (1) formed inside said mold;

f) deburring the burrs existing in the shower tray (1) formed; Y

g) clean the existing mold release agents on the surface of the shaped shower tray (1).

In the event that the geometry of the floor where the shower tray (1) is to be located, does not correspond to the geometry of said shower tray (1), then the steps are added: h) Cut the shower tray (1) conformed according to the measures of a hearth where it will be located; Y

i) top off the cut surfaces with a waterproof material.

In view of this description and set of figures, the person skilled in the art will be able to understand that the embodiments of the invention that have been described can be combined in multiple ways within the scope of the invention. The invention has been described according to some preferred embodiments thereof, but it will be apparent to the person skilled in the art that multiple variations can be introduced in said preferred embodiments without exceeding the object of the claimed invention.

Claims

one . - Ergonomic shower tray (1), characterized in that it comprises: a flat base surface (2);

an upper surface (3a) opposite said flat base surface (2), which comprises in its perimeter zone, flat surfaces suitable for the placement of a screen or the like, at least one drain pipe (4) and a drain zone ( 3b) around said conduit comprising at least one slope (3) with an inclination in the defined range between 0.5% and 2% slope, which falls towards the at least one drain conduit (4) and an adjacent area ( 3c) to the drain zone (3b) defined by the remaining flat surface of said upper surface (3a) of the shower tray (1);

where the thickness of the plate is between 1.75 cm and 3.25 cm and where the material of said shower tray (1) comprises integral polyurethane that defines a plurality of internal cavities to the shower tray (1), providing it with elasticity so that the plate is adaptable to the footprint of a user.

2. - Ergonomic shower tray (1) according to claim 1, characterized in that the upper surface (3a) comprises a waterproofing surface or skin of reduced thickness, which prevents the passage of water or the formation of water remains due to osmosis

3. - Ergonomic shower tray (1), according to any of the preceding claims, characterized in that the drain zone (3b) has a rectangular shape with a larger side between 1 10 cm and 150 cm.

4. - Ergonomic shower tray (1), according to claim 3, characterized in that the drain pipe (4) is offset from the geometric center of the shower tray (1).

5. - Ergonomic shower tray (1), according to any of the preceding claims, characterized in that the upper surface (3a) of the shower tray (1) comprises two zones:

a humid zone defined by the drain zone (3b) comprising said at least one slope (3) and part of the flat perimeter surfaces suitable for the placement of a screen or the like; Y

a drying zone defined by the remaining flat surface of said upper surface (3a) of the shower tray (1).

6. - Ergonomic shower tray (1), according to any of the preceding claims, characterized in that it comprises a plate on the flat base surface (2), aligned in correspondence with the drain duct (4) of the upper surface (3a ) enabled to thread a drain or siphon system inferiorly.

7. - Ergonomic shower tray (1), according to claim 6, characterized in that the plate is made of galvanized iron, reduced thickness and housed at least partially embedded in the flat base surface (2).

8. - Method of manufacturing the ergonomic shower tray (1) defined in any of the preceding claims, characterized in that, from a mold comprising the geometry of said shower tray (1), it comprises the following steps:

a) injecting into the mold a mixture of materials comprising polyol and isocyanate to obtain integral polyurethane, foaming agents and polyurethane pigment;

c) remove the shower tray (1) formed inside said mold.

9. - Method of manufacturing an ergonomic shower tray (1), according to claim 8, characterized in that in step a), the percentage of polyurethane pigment is in the defined range between 2% and 5% of the total material mix.

10. - Method of manufacturing an ergonomic shower tray (1), according to any of claims 8 and 9, characterized in that prior to step a), the process comprises the following steps:

a1) apply mold release agents on the inner surface of the mold that forms the geometry of the shower tray (1) to be shaped; Y

a2) paint said, at least one, inner surface of the mold of a final color of the shower tray (1) to be formed.

eleven . - Method of manufacturing an ergonomic shower tray (1), according to claim 10, characterized in that after stage c), the process comprises the following steps:

c1) deburring the burrs existing in the shower tray (1) formed; Y

c2) clean the existing mold release agents on the surface of the shaped shower tray (1).

12. - Method of manufacturing an ergonomic shower tray (1), according to any of claims 8 to 1, characterized in that subsequent to step c), the process comprises the following steps:

d) cut the shower tray (1) formed according to the measures of a hearth where it will be placed; Y

e) top off the cut surfaces with a waterproof material.

13. - Method of manufacturing an ergonomic shower tray (1), according to any of claims 8 to 12, except for claim 1, characterized in that subsequently to step c), the method comprises the application of an antibacterial treatment based on silver ions.

14. - Method of manufacturing an ergonomic shower tray (1), according to claim 1 and any one of claims 8 to 12, characterized in that subsequently to step c2), the method comprises the application of an antibacterial treatment based on silver ions.

15. - Method of manufacturing an ergonomic shower tray (1), according to any of claims 8 to 13, except for claim 1, characterized in that after step c), the method comprises the application of a non-slip treatment based on non-slip polyurethane.

16. - Method of manufacturing an ergonomic shower tray (1), according to any of claims 1 1 and 14, characterized in that after step c2), the method comprises the application of a non-slip treatment based on non-slip polyurethane .